Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
  • B01J29/405—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07D—HETEROCYCLIC COMPOUNDS
  • C07D213/00—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members
  • C07D213/02—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members having three double bonds between ring members or between ring members and non-ring members
  • C07D213/04—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members having three double bonds between ring members or between ring members and non-ring members having no bond between the ring nitrogen atom and a non-ring member or having only hydrogen or carbon atoms directly attached to the ring nitrogen atom
  • C07D213/06—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members having three double bonds between ring members or between ring members and non-ring members having no bond between the ring nitrogen atom and a non-ring member or having only hydrogen or carbon atoms directly attached to the ring nitrogen atom containing only hydrogen and carbon atoms in addition to the ring nitrogen atom
  • C07D213/08—Preparation by ring-closure
  • C07D213/09—Preparation by ring-closure involving the use of ammonia, amines, amine salts, or nitriles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
  • B01J37/0027—Powdering
  • B01J37/0045—Drying a slurry, e.g. spray drying
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/08—Heat treatment
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07D—HETEROCYCLIC COMPOUNDS
  • C07D213/00—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members
  • C07D213/02—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members having three double bonds between ring members or between ring members and non-ring members
  • C07D213/04—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members having three double bonds between ring members or between ring members and non-ring members having no bond between the ring nitrogen atom and a non-ring member or having only hydrogen or carbon atoms directly attached to the ring nitrogen atom
  • C07D213/06—Heterocyclic compounds containing six-membered rings, not condensed with other rings, with one nitrogen atom as the only ring hetero atom and three or more double bonds between ring members or between ring members and non-ring members having three double bonds between ring members or between ring members and non-ring members having no bond between the ring nitrogen atom and a non-ring member or having only hydrogen or carbon atoms directly attached to the ring nitrogen atom containing only hydrogen and carbon atoms in addition to the ring nitrogen atom
  • C07D213/08—Preparation by ring-closure
  • C07D213/09—Preparation by ring-closure involving the use of ammonia, amines, amine salts, or nitriles
  • C07D213/10—Preparation by ring-closure involving the use of ammonia, amines, amine salts, or nitriles from acetaldehyde or cyclic polymers thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/10—After treatment, characterised by the effect to be obtained
  • B01J2229/18—After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/10—After treatment, characterised by the effect to be obtained
  • B01J2229/20—After treatment, characterised by the effect to be obtained to introduce other elements in the catalyst composition comprising the molecular sieve, but not specially in or on the molecular sieve itself
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/30—After treatment, characterised by the means used
  • B01J2229/42—Addition of matrix or binder particles
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/50—Improvements relating to the production of bulk chemicals
  • Y02P20/584—Recycling of catalysts

Definitions

• the present invention relates to an improved process for pyridine base synthesis, and to specified zinc containing zeolite based catalysts for use in the same.
• Nitrogen-containing compounds are used as structural components of pharmaceuticals and agrochemicals due to their high biological activity.
• pyridine bases are produced in by far the largest quantity and are used in various applications such herbicides, insecticides, pharmaceuticals and adhesives.
• the base synthesis of pyridine and its derivatives is well known.
• the process generally involves reacting aldehydes and/or ketones with ammonia in the gas phase using a heterogeneous catalyst either in a fixed bed or fluidized bed reactor at temperatures ranging from about 400°C to about 450°C.
• the reaction generates coke and the catalyst has to be regenerated with air.
• the use of a fluidized bed provides a useful continuous regeneration system.
• Catalysts used in pyridine base synthesis reactions have varied from alumina either alone or as a support, to amorphous silica alumina (see e.g., U.S. Pat. Nos. 3,272,825; 3,946,020; and 4,089,863) and/or metal substituted silica alumina (see e.g., R.A. Sheldon and H. van Bekkum, Fine Chemicals through Heterogeneous Catalysis, Ed:, Wiley p 277).
• amorphous silica alumina see e.g., U.S. Pat. Nos. 3,272,825; 3,946,020; and 4,089,863
• metal substituted silica alumina see e.g., R.A. Sheldon and H. van Bekkum, Fine Chemicals through Heterogeneous Catalysis, Ed:, Wiley p 277.
• shape selective zeolite e.g.
• metal substituted ZSM-5 zeolites For example, zeolites ion-exchanged with thallium, lead or cobalt showed increased yields of pyridine bases (see e.g., U.S. Pat. No. 4,810,794).
• Other metal substituted zeolites used in pyridine catalysts have included ZSM -5 zeolites modified with one or more metal ions of zinc, tin or tungsten, (see for example, U.S. Pat. No. 5,218,122).
• the essence of the present invention lies in the discovery that a relationship exists between the Lewis (L) acid to Bronsted (B) acid ratio (L/B ratio) and the catalytic activity of a zinc modified zeolite based catalyst to increase the overall yields of pyridine during a base synthesis reaction.
• L/B ratio Lewis (L) acid to Bronsted (B) acid ratio
• a zinc modified zeolite based catalyst having an L/B ratio ranging from about 1.5 to about 4.0 exhibits a significant improvement in pyridine yield as compared to yields obtainable using a zeolite based catalyst containing no zinc.
• Zinc modified zeolite based catalysts in accordance with the invention also exhibit an activity for overall yield increases of pyridine when compared to the activity of similarly zinc modified zeolite based catalysts having a L/B ratio of less than about 1.5 or greater than about 4.0.
• alkyl aldehydes and/or ketones are reacted with ammonia, and optionally, formaldehyde, in a gas phase in the presence of an effective amount of a zinc modified zeolite based catalyst having an L/B ratio ranging from about 1.5 to about 4.0.
• Catalysts of the invention generally comprise a ZSM-5 and/ or ZSM-11 zeolite, zinc, a binder, clay and optionally a matrix material.
• the zeolite is ZSM-5.
• Catalyst compositions of the invention possess an L/B ratio ranging from about 1.5 to about 4.0.
• Yet another advantage of the present invention is to provide a method of enhancing the catalytic activity of a zinc containing zeolite based catalyst to produce increased overall yields of pyridine and its alkyl pyridine derivatives during a base synthesis reaction.
• the method involves adjusting the components of the catalyst to provide specified L/B ratios, as measured by diffuse reflectance I spectrum, in the catalyst composition, which ratios unexpectedly correlate to an increase in the overall yields of pyridine bases during a base synthesis reaction.
• the present invention is directed to improved processes and catalyst compositions for use therein which provides an increase in the overall yields of pyridine and its alkyl derivatives during a base synthesis reaction.
• base synthesis of pyridine and its alkyl derivatives is conducted in the presence of an effective amount of a particulate zinc containing zeolite based catalyst having a specified L/B ratio.
• Catalyst compositions useful in the present invention generally comprises a ZSM-5 and/or a ZSM-11 zeolite, zinc, a binder, clay and optionally, a matrix material, in amounts sufficient to provide the specified L/B ratio.
• base synthesis is used herein to identify a process by which bases of pyridine or alkyl pyridine are prepared by reacting aldehydes and/or ketones with ammonia in the gas phase using a heterogeneous catalyst.
• base synthesis reactions include: the synthesis of pyridine and beta-picoline from acetaldehyde and formaldehyde (the "pyridine-beta reaction”); the synthesis of alpha-and gamma-picoline from acetaldehyde (the “alpha-gamma reaction”); the synthesis of 2,6-dimethylpyridine ("2, 6-lutidine") from acetone and formaldehyde; the synthesis of 2,4,6-trimethylpyridine (“sym-collidine”) from acetone alone or with acetaldehyde; the synthesis of pyridine and beta-picoline from acrolein alone or with acetaldehyde; the synthesis of 3,5-dimethylpyridine from propionaldehyde and formaldehyde; and the synthesis of beta-picoline from acetaldehyde, formaldehyde and propionaldehyde. Many others are known and reported or practiced in
• Zeolites useful to prepare catalysts in accordance with the invention generally include ZSM-5 and/ or ZSM-11 zeolites.
• the zeolite is ZSM-5.
• the zeolites useful to prepare catalyst of the invention possess a silica to alumina ratio of about 100 or less. In a preferred embodiment, the zeolites have a silica to alumina ratio of about 20 to about 80. In an even more preferred embodiment of the invention, the zeolites possess a silica to alumina ratio of about 28 to about 55.
• the binder performs the all important function of holding the components of the catalyst compositions together. However, it is within the scope of the invention that the binder may also provide some catalytic activity. Suitable binders contemplated for use in the catalyst compositions of the invention typically include, but are not limited, to silica, alumina, silica-alumina and combinations thereof.
• the binder is alumina.
• the alumina binder is a gamma alumina that has been derived from an aluminum sol, colloidal alumina, peptized alumina, aluminum chlorohydrate and/or other aluminum precursors.
• Catalysts useful in the present invention also include clay. While kaolin is the preferred clay component, it is also contemplated that other clays, such as pillard clays and/or modified kaolin (e.g. metakaolin), may be included in catalyst compositions useful in the present invention.
• kaolin is the preferred clay component, it is also contemplated that other clays, such as pillard clays and/or modified kaolin (e.g. metakaolin), may be included in catalyst compositions useful in the present invention.
• a matrix material may optionally be present in catalyst compositions useful in the present invention.
• suitable matrix materials include metal oxides, e.g. alumina, silica, silica- alumina, oxides of transition metals and combinations thereof.
• the matrix materials include alumina, silica, silica-alumina and combinations thereof.
• Catalyst compositions useful in the present invention have an L/B ratio of about 1.5 to about 4.0.
• the catalyst compositions have an L/B ratio ranging from about 2.0 to about 3.6.
• the L/B ratio may be obtained by adjusting the concentration of any or all of the catalyst components during catalyst formulation to provide the desired L/B ratio.
• the particulate catalyst compositions of the invention are useful in a base synthesis process typically operated in a fixed bed or fluidized bed reactor, e.g. FCC catalytic cracking unit, to achieve an overall increase in pyridine and alkyl pyridine yields.
• the catalyst compositions are typically in the form of spherical particles and have a particle size and an attrition property sufficient to affect fluidization properties within a fixed bed or fluidized bed reactor.
• catalyst compositions of the invention will typically have a mean particle size of about 40 ⁇ to about 200 ⁇ . In a preferred embodiment of the invention, the catalyst compositions have a mean particles size ranging from about 60 ⁇ to about 120 ⁇ .
• Catalyst compositions used in the present invention will possess an attrition resistance, as measured by Davison Index (DI), sufficient to maintain the structural integrity of the compositions in the fixed bed or fluidized bed reactor. Typically, a DI value of less than 20 will be sufficient. In a preferred embodiment of the invention, the DI value is less than 10.
• DI Davison Index
• each of the components in the catalyst compositions will vary depending on such factors as the desired L/B ratio, the particle size, the attrition resistance, the reactor to be used, etc.
• the amounts of zeolite, zinc, binder, clay and optionally matrix components present in the catalyst compositions used in the invention will vary within a wide range, e.g. about 1-99% by weight, respectively for each component, based upon the total weight of the composition, provided however, that each component is used in an amount sufficient to provide the desired L/B ratio, particle size and attrition resistance for use of the final catalyst composition in a fixed bed or, preferably, a fluidized bed reactor.
• the amount of zeolite ranges from about 35 wt % to about 50 wt % of the catalyst composition.
• the binder amount ranges from about 10 wt % to about 30 wt% of the catalyst composition.
• the clay component will preferably comprise from about 30 wt % to about 50 wt % of the total catalyst composition.
• the matrix material When used, the matrix material will typically comprise the remainder of the catalyst. All of said weight percentages recited herein above is based on the total weight of the final catalyst composition.
• Zinc may be incorporated into the catalyst composition by treatment on the zeolite before or after the zeolite is formulated with the binder, clay and optionally matrix components to prepare the final catalyst compositions. Alternatively, zinc may be incorporated during catalyst formulation as a component of the catalyst. Further, zinc may be exchanged onto the preformed catalyst following catalyst formulation.
• the zeolite may be modified through treatment with metal ions or compounds of zinc.
• Suitable zinc compounds include, but are not limited to, soluble salts such as nitrates, halides or acetates.
• Treatment of the zeolites may be carried out in any number of ways known in the art (such as for example, U.S. Patent 5,218,122, said patent herein incorporated by reference in its entirety) and may be carried out several times if desired to ensure substantial metal uptake on the zeolite.
• the zeolite is added to an aqueous solution of the desired amount of zinc compound in stoichiometric excess to obtain a mixture.
• the mixture is heated at a predetermined temperature and time with stirring.
• the mixture is filtered, rinsed, dried and then calcined at elevated temperature, e.g. about 100°C to about 600°C to obtain the modified zeolite.
• a physical mixture of the zeolite and the desired zinc salt is accomplished either dry or in the presence of water in an amount sufficient to obtain a paste or similar consistency, by blending, mixing or other suitable physical means.
• the final catalyst compositions may be prepared by any conventional means known in the catalysis arts.
• catalyst compositions in accordance with the present invention are formed from an aqueous slurry which comprises an amount by weight of the zeolite, optionally zinc, binder, clay and optional matrix materials.
• the amounts of the catalyst components, i.e. zeolite, optionally zinc, binder, clay and optional matrix materials, are adjusted in the slurry to provide an amount of each component sufficient to obtain the desired L/B ratio, particle size and attrition resistance in the final catalyst composition.
• Zinc may be present in the slurry as zinc ions pre-exchanged on the zeolite prior to incorporation into the aqueous slurry as described herein above.
• zinc may be present in the aqueous slurry as a component thereof in the form of a salt solution of zinc, e.g. zinc nitrates, halides and/or acetates as described herein above.
• the aqueous slurry is subjected to a spraying step using conventional spray drying techniques. During the spray drying step, the slurry is converted to a particulate solid composition.
• the spray dried catalyst particles typically have an average particle size on the order of about 40 to about 200 ⁇ . Following spray drying, the catalyst particles are calcined at temperatures ranging from about 150°C to about 600°C for a period of about 4 hours to about 10 minutes.
• the preformed catalyst particles may be ion exchanged with zinc, in the amount desired in the final catalyst composition.
• the catalyst particles may be impregnated, e.g. via incipient wetness, with an aqueous salt solution of zinc to impregnate zinc ions onto the calcined catalyst particles.
• the catalyst particles may thereafter by washed, preferably with water and the washed catalyst particles are separated from the slurry by conventional techniques, e.g. filtration, and dried to lower the moisture content of the particles.
• the process of the invention provides an increase in the overall yields of pyridine or its alkyl pyridine derivatives produced during a base synthesis reaction.
• Significant improvement in overall pyridine yields i.e. greater than 2%, were achieved when compared to yields obtained using a zeolite based heterogeneous catalyst which contain no zinc.
• Improved overall pyridine yields i.e. greater than 70%, were also achieved over similar zinc containing zeolite based catalyst having a L/B ratio of less than about 1.5 or greater than about 4.0.
• alkyl aldehydes and/or ketones are reacted with ammonia, and optionally, formaldehyde, in a gas phase in the presence of an effective amount of a particulate catalyst composition as described hereinabove in fixed bed or fluidized bed reactor to achieve an unexpected overall increase in yields of pyridine and it alkyl derivatives.
• the equipment set up and operation of fluid-bed reactors vary according to many factors tied to the particular reaction under consideration. The same are readily constructed by those of ordinary skill in the art, and are all within the scope of the invention herein. Reaction parameters such as temperature, feed mole ratios, feed velocity and contact time and the like vary over a wide range of operable conditions also well known and within the scope of the invention.
• At least a portion of the formaldehyde can further be replaced by paraformaldehyde or sym- trioxane, and water can be present as desired to provide a stable, storable solution.
• Ammonia is supplied in a ratio of at least about 0. 6:1 to the total organic components in the feed, with a range of about 0.7 to 1.5 being more preferred and about 0.8 to 1.2 being most preferred from testing to date.
• the feed rate is in turn chosen to give good fluidization of the bed, usually in the range of a superficial velocity between about 0.3 to 4.0 ft/sec.
• Temperature of the reaction is preferably between about 350°C and 550°C more preferably between about 400°C and 500°C and most preferably at about 450°C.
• the products of the reaction being pyridine and beta-picoline, are condensed and separated into pure compounds by drying and distillation as is well known in the art.
• the alpha-gamma reaction is preferably carried out in much the same way except that formaldehyde and methanol are left out of the feed mixture.
• any range of numbers recited in the specification or claims, such as that representing a particular set of properties, units of measure, conditions, physical states or percentages, is intended to literally incorporate expressly herein by reference or otherwise, any number falling within such range, including any subset of numbers within any range so recited.
• Catalysts A, B, C, D and E were prepared using ZSM-5 with a silica /alumina ratio of 28 or 55.
• Zinc chloride was added into an aqueous slurry of zeolite, an alumina binder and clay and the slurry was spray dried using standard spray drying procedures. The spray dried particles were calcined at a temperature of 593.3°C (1100°F) to obtain the final catalysts.
• Compositions of the catalysts following spray drying and calcination were as shown in Table 1 below.

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